ABB CI820 3BSE013200R1 S800 Redundant Communication

I. Overview

The ABB CI820 3BSE013200R1 is a PROFIBUS DP interface module designed for bus communication in industrial automation systems. Its core positioning is a "highly reliable data interaction bridge between ABB AC 800M controllers and PROFIBUS DP slave devices". Its core value lies in establishing a bus-based data transmission network of "AC 800M Controller - Distributed I/O Modules - Third-party PROFIBUS Devices - Upper-level Monitoring System" through in-depth adaptation to the PROFIBUS DP protocol, redundant communication architecture, and industrial-grade stability design. It provides an integrated solution of "bus protocol conversion + redundant communication guarantee + fail-safe protection" for industries such as petrochemicals, electric power, and metallurgy that have strict requirements for communication real-time performance (e.g., millisecond-level data refresh) and reliability (e.g., redundant backup). This addresses the core pain points in industrial systems, including poor device compatibility, high risk of communication interruption, and data transmission delays.

• It is specifically designed for the AC 800M controller, enabling seamless integration into the ABB System 800xA automation platform to achieve integrated configuration and monitoring of "controller - module - slave device".

• It supports dual redundancy for the PROFIBUS DP master station (with automatic switching between primary and backup channels), with a switching time of ≤10ms in case of communication interruption, ensuring uninterrupted data transmission.

Whether for distributed I/O data acquisition in large-scale refineries or PROFIBUS device control in power plant units, its high compatibility and redundant reliability ensure stable and efficient system communication.

II. Technical Specifications

(I) Communication Performance Specifications

(II) Redundancy and Safety Specifications

(III) Environmental and Physical Specifications

III. Functional Features

(I) In-depth AC 800M Integration for Integrated Configuration and Monitoring

• Seamless System Connection: Specifically designed for the ABB AC 800M controller, it can be directly inserted into the AC 800M rack (e.g., PM864 controller rack) and communicates with the controller via the rack bus, requiring no additional wiring. It is compatible with ABB Control Builder M configuration software, enabling module parameter configuration (e.g., communication rate, slave address), slave device mapping (e.g., mapping DI signals of IM153-4 to input variables of the AC 800M), and online debugging in the same software environment. This achieves integrated management of "controller - module - slave device" and improves configuration efficiency by 40%.
• System 800xA Linkage: Supports real-time data interaction with the ABB System 800xA platform, allowing the operating status of PROFIBUS slaves (e.g., slave offline, data refresh cycle) and module fault information (e.g., bus short-circuit, power anomaly) to be uploaded to the 800xA HMI. Maintenance personnel can remotely monitor the module's operating status in the central control room without on-site inspection (e.g., checking the "Slave 12 Offline" alarm via the HMI to directly locate the faulty device).

(II) Dual Redundant Communication Guarantee for Uninterrupted Data Transmission

• Dual Redundancy for Master Station and Bus: Two CI851 modules can be configured for primary-backup redundancy. The primary module handles normal communication, while the backup module synchronizes parameters of the primary module (e.g., slave address, communication rate) in real time. When the primary module fails (e.g., communication chip failure), the backup module takes over communication within 10ms without data loss. Meanwhile, it supports dual PROFIBUS A/B bus cable connection, automatically switching to the backup cable when a single cable fails due to aging or short-circuit to avoid communication interruption. In the control of petrochemical reactors, the redundant configuration ensures uninterrupted control signals for feed valves (transmitted via PROFIBUS), preventing reactor overpressure risks caused by communication failures.
• Slave Hot-swapping and Fault Isolation: Supports hot-swapping of PROFIBUS slaves (requires slave device support), allowing replacement of faulty slaves (e.g., distributed I/O modules) without shutdown; the module automatically identifies the new slave and resumes communication. When a single slave fails (e.g., offline, data error), the module only isolates the faulty slave without affecting the normal communication of other slaves, increasing system availability to 99.99%.

(III) Wide-ranging Device Compatibility to Reduce System Expansion Costs

• Multi-brand Slave Adaptation: Compatible with PROFIBUS DP slave devices from major brands such as ABB, Siemens, and Schneider. It supports importing slave GSD files (device description files) to automatically identify device models and I/O channels, eliminating the need for manual writing of communication protocol code. In an auto parts factory, the CI851 can simultaneously connect to ABB IM153-4 I/O modules (for sensor data acquisition), Siemens S120 servo drives (for controlling production line motors), and Schneider ATV320 frequency converters (for controlling conveyors), enabling unified bus control of multi-brand devices without additional protocol conversion modules.
• DP V2 Function Expansion: Supports isochronous synchronization (IRT) and acyclic data exchange functions of the PROFIBUS DP V2 protocol. The isochronous synchronization accuracy of ≤1μs is suitable for multi-axis linkage scenarios (e.g., synchronous control of PROFIBUS servo drives in precision machine tools). Acyclic data exchange can be used to transmit large-volume data (e.g., slave device firmware upgrade files, historical fault records) without occupying real-time communication bandwidth, meeting both real-time control and non-real-time data transmission needs.

(IV) Industrial-grade Stable Design for Harsh Environments

• Wide Temperature Range and Strong EMC Immunity: The wide temperature range of -25℃ to +60℃ covers outdoor control cabinets in northern winter (e.g., outdoor power distribution rooms of power plants) and high-temperature workshops in southern summer (e.g., steel rolling workshops in metallurgical plants). The EMC immunity against ±8kV ESD contact discharge and ±4kV EFT burst can resist electromagnetic interference from workshop motors and frequency converters, with a communication data error rate of ≤10??, ensuring stable transmission of PROFIBUS signals (e.g., no fluctuations in reactor temperature sensor data).
• Durable Hardware and Protection: Interface terminals undergo gold-plating anti-oxidation treatment, with a contact resistance of ≤10mΩ, capable of resisting corrosion from corrosive gases (e.g., hydrogen sulfide) in chemical workshops and extending terminal service life to over 5 years. PROFIBUS interfaces are equipped with dust covers to prevent dust ingress when not in use and protect interface contacts. The module housing is made of flame-retardant ABS material, complying with UL 94 V-0 flame-retardant standards to enhance safety in industrial sites.

(V) User-friendliness and Maintenance Optimization to Reduce Operation Costs

• Local and Remote Debugging: The Mini USB interface supports local parameter configuration (e.g., modifying communication rate, slave address) and exporting fault logs (including fault time and fault code) via a laptop. It also supports remote access to the module via the AC 800M controller for parameter modification (e.g., slave mapping relationship) and firmware upgrade (online upgrade via Control Builder M software), eliminating the need for on-site trips for maintenance of remote sites (e.g., remote firmware upgrade for hydropower stations in mountainous areas saves 2 days of maintenance time).
• Visual Status Feedback: The module panel is equipped with three-level LED indicators for power, bus, and slaves. A red power light indicates a module fault, a yellow primary bus light indicates abnormal primary bus communication, and a red slave light indicates a fault in the corresponding group of slaves. Maintenance personnel can locate the fault level within 10 minutes using the indicators (e.g., "red light on for slaves 33-64 group" indicates a faulty slave in that group), improving fault detection efficiency by 60%.

IV. Application Scenarios

Petrochemical Industry: Distributed I/O Data Acquisition for Reactors

Electric Power Industry: Auxiliary Equipment Control for Power Plant Units

Metallurgical Industry: Multi-device Collaboration in Rolling Mill Production Lines

Automotive Manufacturing: Robot Control in Welding Workshops